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Custom Engineering HV Power Supplies for High Performance Applications

By Uwe Uhmeyer Product Line Leader, Excelitas Technologies, High Voltage Power


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High voltage power supplies (HVPS) are required in a multiplicity of configurations and

capabilities. Dimensions, type of enclosure, weight, input and outputs, thermal and

electromagnetic interference (EMI) shielding, cooling method, connectors, etc., can vary

with each application. While some manufacturers offer standard products that can be sold

“off-the-shelf,” HVPS applications most often mandate customization. Depending on the

specifications, regulatory requirements, development schedule of the OEM1, suitability of

an existing platform, customer changes, and other factors, the process can take as long as

a year to complete. A “designed from scratch” HVPS will take even longer.

Excelitas Technologies designs and manufactures high performance, high reliability

power supplies for the unique requirements of a particular customer and application.

Products developed by the company provide power levels to 100kW, with output

voltages that range from 300 V to 750 kV. Excelitas power supplies are customized for

specific applications, with dozens of new models being developed each year. This paper

discusses some of the design and performance parameters that must be accommodated in

engineering to design and produce a HVPS.

Engineering Considerations in Designing an HVPS

HVPS belong to a diverse family of devices that provide electrical power to electronic

circuitry. Types include AC to DC power supplies, DC to DC converters, and controlled

current power supplies. Virtually all new HVPS are designed using switch mode

technology, in order to achieve high performance while keeping the size small and costs

low. The list of switch mode topologies is long and each has performance advantages in

certain areas or applications. It should also be noted that in many cases, the HVPS needs

to provide several outputs.

Variations also exist in terms of how the power supply is packaged, with bare circuit

boards, modules, open frames, enclosed frames, and rack mounts being typical variations.

1 OEM = Original Equipment Manufacturer


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Large HVPS systems may be housed in cabinets. Figure 1 depicts various modular

HVPS supplies and two larger rack-mounted units.

Figure 1. Excelitas Modular and Rack-Mounted High Voltage Power Supplies

The choice of insulation system in a HVPS is usually driven by the output voltage and

output power as well as the packaging. Typical insulation systems are based on air,

dielectric oil, epoxy, RTV Silicone Rubber and Sulfur Hexafluoride (SF6). The method of

cooling is a factor as well, the choices often coming down to air, water or oil, depending

on the platform design, the amount of heat to be dissipated, the output voltage, and

installation infrastructure considerations. Figure 2(a) on the next page is a photograph of

an RTV Silicone Rubber filled housing which encases an Excelitas Medical X-ray power

supply and Figure 2(b) is an oil filled housing containing an Excelitas HV supply. Then,

there are the particular features required by the application, such as power factor

correction; number and adjustability of outputs; and the user interface or control.

Typical controls include local front panel (analog or digital), electrical interface including

analog and digital signals as well as computer interfaces including USB, Ethernet, RS232

and GPIB.


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Figure 2(a): Potted HV Encasement Figure 2(b): Oil filled HV Encasement

For low and medium voltage requirements, an off-the-shelf power supply can sometimes

meet the needs of the application. On the other hand, high voltage power requirements

almost always call for a unique solution, primarily because an existing power supply can

seldom be found to satisfy the particular combination of specifications governing

performance, packaging, cooling, and physical dimensions. Safety and risk reduction

concerns also play a role. For example, designed-in protection from load arcing, EMI

effects, and drops in input line voltage ensure equipment integrity, while design

measures, such as interlock circuitry, low storage of energy due to high frequency

operation, and control circuit regulation of the output, are intended to protect personnel,

as well as the equipment.

The definition of “high voltage” varies depending on the context. Safety agencies

reviewing electronic circuits generally define greater than 48 V as high voltage while the

National Electric Code (NEC) specifies “greater than 600 volts”. Sometimes an arbitrary

level such as greater than or equal to 1 kV may be considered high voltage. For the

purposes of this paper, Excelitas demonstrates High Voltage products ranging from

300 V to 750 kV.

Despite the dissimilarities in design and performance, HVPS are generically configured

as shown in Figure 3, consisting of an EMI filter, power factor correction (PFC) circuitry,

rectifier, inverter, high voltage transformer, multiplier/rectifier-filter, high voltage


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divider, and feedback control system. How these components are configured in the

circuitry depends on the type of HVPS and the topology approach taken by the design

engineer in meeting the specifications. The input voltage can be either AC or DC, with

lower power units sometimes employing DC (up to 48 Vdc) and higher power supplies

designed for AC (115 Vac to 480 Vac)2 or higher voltage DC (200 Vdc to 385 Vdc).

Figure 3. Block Diagram of a typical HVPS

As shown in Figure 3, input power is initially fed through an EMI filter and a rectifier

stage to produce DC (by converting the input, if AC) and to filter out spurious noise. The

rectifier also incorporates circuitry for power factor correction to minimize the phase

angle, between the current and voltage waveforms for achieving a good power factor

(real power divided by apparent power) greater than 0.84 and even as high as 0.99.

Power factor correction (PFC) can be either passive or active. Passive circuitry, which is

the technique generally preferred for high power units, consists of an inductor and

capacitor network, and can often produce a power factor as high as 0.94 when measured

2 The most common DC input voltages are 12 and 24 Vdc. AC voltages often depend on the country.

115/230 Vac, 60 Hz, for example, is the standard in the U.S., while the standard for most of Europe is

240 Vac, 50 Hz. Line voltage in Asian countries differs from both the U.S. and Europe. Power supplies can

also be designed to accommodate a range of input voltage.


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at full power. Active PFC can produce a power factor in excess of 0.98 over the full

range of power output of the HVPS. CE standards enacted by the European Union, for

instance, may apply in terms of harmonic content for some applications which are often

met by use of an active PFC. An additional benefit of active PFC is the fact that a

regulated DC rail results, often making the line regulation of the HVPS so good as to

make it virtually immeasurable. Passive circuitry will produce a DC rail with a value

dependent upon the magnitude of the AC line. Excelitas is able to engineer both single-

phase and three-phase active power factor correction, as well as passive PFC.

Referring again to Figure 3, the resulting DC voltage output from the filter is applied to a

resonant inverter, which then produces a high frequency AC signal. The inverter drives

the primary windings of the high voltage “step up” transformer, the next stage in the

process. The inverter can represent a formidable aspect of the power supply design, in

that particular care must be taken to ensure high reliability and efficiency and to achieve

the desired degree of margin with regard to component rating.3

Though the signal flow and the stages shown in Figure 3 are well understood, the actual

topologies can be complicated and challenging to the engineer in creating a stable power

supply output that meets the requirements of the customer and the application. The

transformer, for instance, involves careful consideration of such factors as the core

geometry, the number of primary and secondary turns, how the turns are wound, and the

type and method of layer-to-layer insulation. It is here that problems can occur in terms

of capacitance, insulation breakdown, thermal degradation and other undesirable

conditions. As with the inverter stage, extensive engineering experience and the

application of “tried and true” methods are essential for a viable design.

The next stage is the high voltage multiplier, which consists of a network of high voltage

diodes and capacitors for rectifying, filtering, and multiplying the transformer voltage.

The design process involves circuit analysis, prototyping, and testing to ensure the

3 Margin can be defined as the difference between the maximum capability of a component and the actual

“use” requirement of a circuit. Thus, the transistor rated for 1000 volts and installed in a 600 volt system

would have a margin of 400 volts.


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desired results. The circuitry must be protected from the high energy released when load

capacitors are discharged (voltage reversal); and, in general, the power supply must be

able to withstand both high current and large voltage transients. The design of a HVPS

for powering an X-ray tube is an example of the circuit protection required, in that the

transient effects of arcing must be tolerated by the HVPS while it manages the overall

system’s arc response.

The final stage, for most requirements, is a compensated high voltage divider with a

feedback loop. The divider requires careful design to achieve the necessary transient

response, limit overshoot, and perform satisfactorily during normal turn-on and turn-off

operation. The basic premise is for the AC division ratio to be equal to the DC division

ratio of the feedback divider so that the HVPS will accurately regulate during transient

conditions (HV turn on, turn off, load discharge, arcing). Also it is very important that a

properly designed high voltage divider allows for an accurate high-voltage monitor that

will faithfully indicate what is happening at the high-voltage output in real time.

As shown in Figure 3, the control circuit incorporates an auxiliary low-voltage power

supply, called a “housekeeping” supply, for running control circuits (regulator, fault

logic, remote control, etc.) When needed, additional functionality can be incorporated

into the HVPS design. An example is the “Omniblock,” a complete X-ray source that

incorporates the X-ray tube and its cooling system with the HVPS into a single compact

enclosure.

HVPS Applications for Excelitas

Because of the ranges of voltage and power available from Excelitas, power supplies can

meet the requirements of a number of market segments and be incorporated in a wide

variety of OEM equipment. Table 1 provides a partial listing of applications and

products.


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Table 1

Market Segments and Representative End Uses For HVPS

Market Segments/Applications Representative End Uses

Analytical/Laboratory Equipment Chemical/Element Analysis

Electron Microscopy

Mass Spectrometry

Microfluidics

UV Spectroscopy

X-Ray Fluorescence, X-Ray Diffraction

Industrial X-Ray Inspection/NDT Microfocus and Nanofocus Inspection of PCBs, Flex Circuits, and Components

Inspection of Fabricated Parts and Welds

Inspection of Ceramics and Plastics (Structure, Alignment, Porosity, etc.)

Materials Processing Air/Water Purification

Chemical Processing

Food Inspection

Ink Processing

Metalworking and Fabrication

Pharmaceutical Processing

Medical (Imaging) Bone Densitometry

CT Scanning

Gamma Camera Imaging

Mammography

MRI Scanning

PET Scanning

Medical (Treatment) Dermatology

Lithotripsy

Ophthalmology

Radiation Oncology

Security Baggage X-Ray Screening

Explosive Detection (EDS): Automated In-Line and Check Point Systems

Explosive Trace Detection (ETD)


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Market Segments and Representative End Uses For HVPS (cont’d.)

Market Segments/Applications Representative End Uses

Semiconductor Manufacturing Electron Beam Lithography

Electrostatic Coating

Ion Beam Implantation

Physical/Chemical Vapor Deposition

Instrumentation

Government/Defense Avionics Displays

Secured Communications

Electronic Countermeasures

Flight Simulation

RF Amplification and Microwave Heating with Klystrons/ Magnetrons

Weaponry: Laser Guidance and Plasma Propulsion Systems

Radar

Night Vision

Laser Ranging

CRT

Certain products “cross the line” with regard to market segments. HVPS, for instance, are

used to power lasers for such purposes as medical treatment, optical inspection, precision

X-Y platform alignment, and non-contact welding. X-ray inspection systems, which also

incorporate HVPS (the tube and power supply are sometimes packaged together as a

product), are used for diverse operations ranging from baggage screening in airports to a

host of industrial non-destructive testing applications. Excelitas also designs and

manufactures capacitor charging power supplies for pulsed power applications, in

particular, lasers and flash lamps.

Designing and Developing a Excelitas Power Supply

As stated previously, the process of custom designing and manufacturing a HVPS can

take as long as a year. OEM customers usually do not want a “designed-from-scratch”

power supply, and look to an existing platform technology as a proven, cost-effective


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starting point for a new product. In most instances, an off-the-shelf power supply cannot

be used because of the uniqueness of the design and performance requirements.

In order to meet the development schedule of the OEM system in which the HVPS will

be incorporated, initial key specifications and related details should be provided to

Excelitas by the OEM system designer as soon as possible in the development process.

(“Related details” can include non-specification requirements in terms of materials,

manufacturing process, testing, prototype construction, approved vendors,

documentation, etc.) In fact, early participation by Excelitas can not only smooth and

expedite design and development, but can also enable Excelitas engineering to work with

the customer to optimize the performance and physical specifications (size, weight, type

of enclosure, method of cooling, etc.) for the power supply.

In the initial phases of a custom design effort, Excelitas prefers to visit the customer site

to see the current state of the OEM design and to review expectations that may not be

reflected in the specification. In fact, in most instances, however detailed the

specification may be, not all of the relevant aspects of the design and performance

requirements are likely to have been captured. Visits by Excelitas to the OEM should

include, as a minimum, the project leader and design engineers assigned to the effort.

Routine technical and status discussions between OEM system designers and Excelitas

benefit the customer in terms of schedule, product quality, and cost. Such discussions are

normally conducted over the phone, but may entail visits, off-site meetings, and internet

sessions. From the interaction between Excelitas personnel and the customer, a

conceptual design evolves that accommodates the requirements of the OEM, while

eliminating (or at least minimizing) project delays and ensuring minimal high voltage risk

to equipment and personnel as the process evolves. Project efficiency is also enhanced

because resources (personnel, facility, components, materials, etc.) can be allocated and

schedules established for cost-effectively managing the project.


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It is important to realize that certain specifications or parameters dictate or define the

design approach. Also there usually are a set of specification tradeoffs that occur

between, say, three parameters where in order to optimize the most important one, the

others become more difficult, therefore requiring more material or greater size to achieve

them. It is in these tradeoff decisions that Excelitas personnel can be particularly helpful

to the OEM, avoiding tight specifications that may not be required and might represent an

unnecessary cost to the customer. For DC power supplies, an example of this is output

ripple vs. stored energy vs. transient response/settling. Very low output ripple can be

achieved by adding more output capacitance, but this will increase the stored energy in

the power supply and potentially be more damaging to the load connected to the power

supply. Alternatively, lower ripple can be achieved by higher switching frequencies

which may increase power dissipation or require more expensive semiconductor devices.

Understanding the tradeoffs helps optimize the design for the OEM application.

Similarly there are specification and design tradeoffs in capacitor charging applications.

Charge rate usually trades off against accuracy and repeatability. Faster charge rates

enable higher repetition rates, which increases output power for a given load capacitor

which may increase size and cost. Additionally, it is important to understand the nature of

the discharge characteristic in order to determine the peak or instantaneous power level,

which may be a more important design specification than the average power output

required.

Why Excelitas?

Excelitas products are found in applications where there is no room for error or failure,

such as medical treatment (lasers and other pulsed power products), medical CT, X-ray

inspection, electron and mass spectrometry, and ion beam implantation. For these

applications, and others, precision and reliability ― for the HVPS, as well as the OEM

product ― are paramount. Beyond our history of high voltage experience, which dates

back to 1931, our deep portfolio of enabling technologies and the broad range of


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applications and markets we serve, it is the strength of Excelitas’ 3000+ employees

across the globe that deliver value to our customers on a daily basis. Excelitas’ core

values – Integrity, Customer Focus, Continuous Improvement, Teamwork, and

Organizational Agility - are the foundations that guide all of our actions. We are

committed to enabling our OEM customers’ success in their markets and applications by

supplying innovative, customized power systems, optoelectronics and advanced

electronic systems utilizing innovative, high-performance, market-driven technology

solutions.

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